WO2018173608A1 - 絶縁電線、その製造方法、これを用いたコイルの製造方法及びコイル - Google Patents

絶縁電線、その製造方法、これを用いたコイルの製造方法及びコイル Download PDF

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Publication number
WO2018173608A1
WO2018173608A1 PCT/JP2018/006268 JP2018006268W WO2018173608A1 WO 2018173608 A1 WO2018173608 A1 WO 2018173608A1 JP 2018006268 W JP2018006268 W JP 2018006268W WO 2018173608 A1 WO2018173608 A1 WO 2018173608A1
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WIPO (PCT)
Prior art keywords
inner layer
layer
conductor wire
outer layer
short side
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PCT/JP2018/006268
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English (en)
French (fr)
Japanese (ja)
Inventor
誠 漆原
泰彦 工藤
慎太郎 飯田
桜井　英章
Original Assignee
三菱マテリアル株式会社
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Application filed by 三菱マテリアル株式会社 filed Critical 三菱マテリアル株式会社
Priority to EP18772228.5A priority Critical patent/EP3605558B1/de
Priority to CN201880014473.3A priority patent/CN110352463B/zh
Priority to US16/493,801 priority patent/US11581127B2/en
Publication of WO2018173608A1 publication Critical patent/WO2018173608A1/ja

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/08—Flat or ribbon cables
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/32—Insulating of coils, windings, or parts thereof
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D179/00—Coating compositions based on macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing nitrogen, with or without oxygen, or carbon only, not provided for in groups C09D161/00 - C09D177/00
    • C09D179/04—Polycondensates having nitrogen-containing heterocyclic rings in the main chain; Polyhydrazides; Polyamide acids or similar polyimide precursors
    • C09D179/08—Polyimides; Polyester-imides; Polyamide-imides; Polyamide acids or similar polyimide precursors
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
    • C09D5/44—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes for electrophoretic applications
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/02—Disposition of insulation
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/02—Disposition of insulation
    • H01B7/0208—Cables with several layers of insulating material
    • H01B7/0216—Two layers
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/06—Coil winding
    • H01F41/064—Winding non-flat conductive wires, e.g. rods, cables or cords
    • H01F41/066—Winding non-flat conductive wires, e.g. rods, cables or cords with insulation
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F5/00—Coils
    • H01F5/06—Insulation of windings
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
    • H01B3/18—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
    • H01B3/30—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes
    • H01B3/303—Macromolecular compounds obtained by reactions forming a linkage containing nitrogen with or without oxygen or carbon in the main chain of the macromolecule, not provided for in groups H01B3/38 or H01B3/302
    • H01B3/306—Polyimides or polyesterimides
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/60—Other road transportation technologies with climate change mitigation effect
    • Y02T10/64—Electric machine technologies in electromobility

Definitions

  • the present invention relates to an insulated wire for winding processing in which a conductor wire is covered with an insulating film having a two-layer structure, and a method for manufacturing the same. More specifically, the present invention relates to an insulated wire excellent in adhesiveness with a conductor wire of an insulating film on the inner side of the bend during bending and a method for manufacturing the insulated wire. More specifically, the present invention relates to a coil manufacturing method and a coil using an insulated wire.
  • Patent Document 1 So far, an insulated wire excellent in adhesion between a conductor and an insulating film or a manufacturing method thereof has been proposed (for example, see Patent Document 1).
  • a paint containing a resin for forming a coating film and a polysulfide polymer is applied to the conductor surface in an amount such that the thickness after curing is 4 ⁇ m or more, and then heat-cured.
  • a primer layer having a thickness of 4 ⁇ m or more is formed between the conductor and the insulating coating by one cycle of application and heat curing.
  • the sulfur atom of the polysulfide polymer contained in the primer can form a bond with the conductor (copper) to enhance adhesion, and the polysulfide polymer contained in the primer layer Since it has rubber elasticity, it is said that the peeling strength of the insulating coating can be increased by alleviating external stress applied to the insulating coating.
  • the insulating film formed around the conductive wire is composed of an inner film disposed on the conductive wire side and an outer film disposed around the inner film, and the outer film is compared to the inner film. It has relatively high heat resistance, and the inner coating and the outer coating are in close contact with each other through an engaging portion that engages with each other. Since this winding has a two-layer insulating film, the two-layered insulating film does not separate from each other, and has high adhesion so that it has excellent heat dissipation and tears in the outer film. It is said that it is difficult.
  • the multilayer anion electrodeposition coating-film formation method shown by patent document 3 is an electrodeposition coating of the anion electrodeposition coating material (A) containing a particulate metal oxide with respect to a base material, and is uncured anion electrodeposition.
  • the first step of forming the coating film (A) and the electrodeposition coating of the anionic electrodeposition paint (B) on the substrate on which the uncured anion electrodeposition coating film (A) is formed A second step of forming an uncured anion electrodeposition coating film (B), and baking and curing the uncured anion electrodeposition coating film (A) and the uncured anion electrodeposition coating film (B) at a time.
  • a resistance value of the uncured anion electrodeposition coating film (A) is 25 to 190 k ⁇ ⁇ cm 2 .
  • the coating voltage can be increased.
  • the second anion electrodeposition coating film can be made thick without increasing the energization time, and an excellent appearance can be obtained.
  • Japanese Unexamined Patent Publication No. 2011-192514 (A) (Claim 1, paragraph [0013]) Japanese Unexamined Patent Publication No. 2012-228338 (A) (Claim 1, Paragraph [0014]) Japanese Unexamined Patent Publication No. 2013-111040 (A) (Claim 1, paragraph [0017])
  • the resin used in the primer layer of the insulated wire shown in Patent Document 1 is often inferior in heat resistance and insulation as compared with the resin coated on the outer layer.
  • edgewise bending is performed, and when the outer coating of the bend becomes thin, There was a problem that the insulation and heat resistance at the outer periphery of the bending tended to be inferior.
  • the adhesiveness is improved by using an engagement portion between the inner coating and the outer coating, but the inner coating is most easily peeled off from the metal that is a conductor.
  • the flat wire on which edgewise bending is performed cannot sufficiently improve the adhesion of the inner coating to the conductive wire.
  • the inventors of the present invention have a two-layer structure of an inner layer and an outer layer of an insulating film covering a rectangular conductor wire, and two of the short sides having the same length are opposed to each other in a rectangular cross section of the rectangular conductor wire.
  • the thickness of the inner layer covering one short side of the inner layer is larger than the thickness of the inner layer covering the other short side, and the elastic modulus or yield stress of the inner layer is smaller than the elastic modulus or yield stress of the outer layer, insulation
  • the winding process is performed by edgewise bending which bends the short side of one of the wires with the inner layer being thick, the load on the inner layer at the interface between the inner conductor layer and the inner layer can be absorbed, Focusing on the fact that the adhesiveness of the insulating film on the inner side of the bend is enhanced with the conductor wire, the present invention has been achieved.
  • the first aspect of the present invention is an insulated wire 10 in which a rectangular conductor wire 11 having a rectangular cross section is covered with an insulating film 12, and the insulating film 12 has a rectangular shape.
  • An inner layer 12A that covers the surface of the conductor wire 11 and an outer layer 12B that covers the surface of the inner layer.
  • the modulus is smaller than the elastic modulus of the outer layer 12B, or the yield stress of the inner layer 12A is smaller than the yield stress of the outer layer 12B, or both the elastic modulus and yield stress of the inner layer 12A are smaller than the elastic modulus and yield stress of the outer layer 12B.
  • Insulated wire featuring It is 0.
  • a second aspect of the present invention is an invention based on the first aspect, one of the one short side 11A of the inner layer of the thickness t 1 which covers the short sides 11A, the outer layer covering over the inner layer the ratio to the thickness t 3 (t 1 / t 3 ) is an insulating wire 10 is 1 or less.
  • a third aspect of the present invention is an insulated wire 10 according to the first or second aspect, wherein the insulating film 12 including the inner layer 12A and the outer layer 12B has a thickness of 40 to 65 ⁇ m.
  • a fourth aspect of the present invention is an invention based on any one of the first to third aspects, in which the long side 11C with respect to the short sides 11A and 11B in the rectangular cross section of the flat conductor wire 11 is provided.
  • the insulated wire 10 has a length ratio (long side / short side) of 4 to 50, and the round wire equivalent diameter of the flat conductor wire 11 is 3 to 5 mm.
  • the round wire equivalent diameter refers to the diameter of a perfect circular line having the same cross-sectional area as that of a conductor wire having a cross-sectional shape other than a perfect circle.
  • a fifth aspect of the present invention is an invention based on any one of the first to fourth aspects, wherein the rectangular conductor wire 11 is a copper wire, and the material of the inner layer 12A is a urethane skeleton or a siloxane skeleton.
  • the insulated wire 10 is a polyimide resin or a polyamideimide resin having an outer layer 12B of which the material of the outer layer 12B is a polyimide resin or a polyamideimide resin.
  • a method for producing an insulated wire by electrodepositing an electrodeposition liquid on a rectangular conductor wire having a rectangular cross-sectional shape to form the insulating film The first step of covering the surface of the flat rectangular conductor wire with the inner precursor layer and the surface of the inner layer precursor layer of the flat rectangular conductor wire with the outer precursor layer by the second electrodeposition liquid Including a second step and a third step of baking the inner layer precursor layer and the outer layer precursor layer together to cover the flat conductor wire with two layers of an inner layer and an outer layer, and the flat conductor
  • the thickness of the inner layer precursor layer covering one short side of two short sides opposite to each other in the rectangular cross section of the line is the same as that of the inner layer precursor layer covering the other short side.
  • the first step is performed so as to be larger than the thickness, and a rectangular cross section of the rectangular conductor wire is formed.
  • the thickness of the inner layer precursor layer covering one short side of the two short sides facing each other and having the same length is larger than the thickness of the inner layer precursor layer covering the other short side.
  • the first step is performed, and the content of the first electrodeposition liquid and the content of the second electrodeposition liquid are set so that the elastic modulus of the inner layer is smaller than the elastic modulus of the outer layer, or Insulated wires characterized in that the yield stress is smaller than the yield stress of the outer layer, or that both the elastic modulus and yield stress of the inner layer are smaller than the elastic modulus and yield stress of the outer layer, respectively. It is a manufacturing method.
  • the 7th aspect of this invention is invention based on 6th aspect, Comprising:
  • the said 1st electrodeposition liquid contains the polyimide solution or polyamideimide solution which has a urethane frame
  • the liquid is a method for producing an insulated wire containing a polyimide solution or a polyamideimide solution as a component.
  • a coil by performing winding processing by edgewise bending which bends the insulated wire of any of the first to fifth aspects with the one short side being thicker on the inner layer. It is a method of manufacturing.
  • the insulated wire according to any one of the first to fifth aspects is wound a plurality of times in an edgewise shape bent with the one short side inside the thick inner layer. It is a coil.
  • the insulating film covering the rectangular conductor wire has a two-layer structure of an inner layer and an outer layer, and the rectangular conductor cross-sections of the rectangular conductor wire are opposite to each other and have the same length.
  • the thickness of the inner layer covering one short side of the two short sides is made larger than the thickness of the inner layer covering the other short side, and the elastic modulus or yield stress of the inner layer is changed to the elastic modulus or yield stress of the outer layer. Because it is smaller, when winding is performed by edgewise bending that bends the insulated wire with the short side of the thick inner layer inside, the insulation film at the interface between the inner conductor wire and the inner layer is bent.
  • the inner layer absorbs the compressive stress of the inner layer, prevents peeling and wrinkles in the inner layer, and has an excellent effect in adhesion to the conductor wire of the insulating film inside the bend.
  • the thickness of the material having a low elastic modulus or yield stress is small, there are few scratches that occur during processing, and the insulating properties and heat resistance after processing are excellent.
  • the ratio of the short side of the inner layer t 1 covering one short side to the thickness t 3 of the outer layer covering the inner layer (t 1 /
  • t 3 ) the inner layer thickness is set to be equal to or less than the outer layer thickness, and the occupancy rate of the inner layer is reduced so that the elastic modulus or yield stress is smaller than the elastic modulus or yield stress of the outer layer.
  • the thickness of the insulating film including the inner layer and the outer layer is 40 ⁇ m or more, the dielectric breakdown voltage and the heat resistance are excellent. Further, since the thickness of the insulating film is 65 ⁇ m or less, the adhesiveness of the insulating film on the inner side of the bend to the conductor wire is further improved during bending.
  • the cross-sectional shape of the rectangular conductor wire is rectangular, and the ratio of the length of the long side to the short side in the cross-section (ratio of long side / short side)
  • ratio of long side / short side the ratio of the length of the long side to the short side in the cross-section
  • the round wire equivalent diameter of a conductor wire is 3 mm or more, it can be used as an insulated wire for large currents. Moreover, since the round wire equivalent diameter is 5 mm or less, this insulated wire is further excellent in adhesion to the conductor wire of the insulating film inside the bend during bending. In addition, when a large current flows through an insulated wire, high insulation by a thick insulating film is required, but when the insulating film is thick, wrinkles and peeling due to bending are likely to occur, and in such a case, the present invention is suitable. is there.
  • the conductor wire is a copper wire
  • the conductivity is excellent.
  • the material of the inner layer of the insulating film is a polyimide resin or polyamideimide resin having a urethane skeleton or a siloxane skeleton
  • the material of the outer layer is a polyimide resin or polyamideimide resin
  • the conductor wire of the insulating film on the inner side of the bend during bending Adhesive strength is high, and it has excellent breakdown voltage and heat resistance.
  • the inner layer precursor layer and the outer layer precursor layer covering the rectangular conductor wire are formed by the two electrodeposition steps of the first and second steps, and the inner layer is formed in the third step. Since the precursor layer and the outer layer precursor layer are collectively baked to form the inner layer and the outer layer, these two layers cover the rectangular conductor wire while the inner layer and the outer layer are firmly adhered.
  • the thickness of the inner layer covering one short side of the two short sides opposite to each other in the rectangular cross section of the rectangular conductor wire in the first step, and the inner layer covering the other short side And the elastic component and / or the yield stress of the inner layer are made smaller than the elastic modulus and / or the yield stress of the inner layer.
  • the wire when winding is performed by edgewise bending, in which one short side of the inner layer is thicker, the wire is compressed to the insulation film at the interface between the inner conductor wire and the inner layer.
  • the inner layer absorbs the stress, prevents wrinkles in the inner layer, and has an excellent effect in adhesion to the conductor wire of the insulating film inside the bend.
  • the first electrodeposition liquid contains a polyimide solution or a polyamideimide solution having a urethane skeleton or a siloxane skeleton
  • the second electrodeposition liquid contains a polyimide solution or a polyamideimide solution. Since it is used as a component, it is possible to increase the adhesiveness of the insulating film on the inner side of the bend to the conductor wire and to make the insulated wire have a high dielectric breakdown voltage and high heat resistance.
  • the insulation failure occurs.
  • the insulation film of the insulated wire that causes the above does not peel off from the conductor wire or wrinkles.
  • the coil made of the above insulated wire has excellent adhesion to the conductor wire of the insulation film on the inner side of the bend, so that the film peeling or wrinkle generated by winding processing does not occur.
  • the coil is excellent in insulation.
  • FIG. 3 is a sectional view taken along line XX of FIG. 2 showing a cathode structure in a first step of the present embodiment.
  • FIG. 3 is a cross-sectional view taken along line YY of FIG. 2 showing a cathode structure in a second step of the present embodiment.
  • FIG. 3 is a cross-sectional view corresponding to the cross-sectional view taken along the line XX of FIG. 2 showing the cathode structures of Comparative Examples 1 to 3.
  • the insulated wire 10 of this embodiment is an insulated wire for winding processing in which a rectangular conductor wire 11 having a rectangular cross-sectional shape is covered with an insulating film 12.
  • the rectangular flat shape means that when the insulated wire is wound into a coil, the occupation ratio of the cross-sectional area of the conductor wire in the coil cross-sectional area is reduced. Can be bigger.
  • a characteristic point of the insulated wire 10 is that the insulating film 12 is composed of an inner layer 12A covering the surface of the flat rectangular conductor wire 11 and an outer layer 12B covering the surface of the inner conductor wire 11.
  • the thicknesses of the inner layer 12 ⁇ / b> A and the outer layer 12 ⁇ / b> B of the insulating film 12 are enlarged compared with the dimensions of the flat conductor wire 11.
  • One short side 11A of the flat conductor wire 11 is thickly covered with an inner layer 12A whose elastic modulus and yield stress are smaller than the outer layer, the inner layer surface is covered with an outer layer, and the short side 11A is bent by an edgewise bending process.
  • the inner side even if compressive stress due to bending acts intensively on the site where peeling or wrinkling is likely to occur, the burden on the interface between the conductor wire and the insulating film can be reduced, and insulation It becomes an insulated wire that does not peel off or wrinkle.
  • the elastic modulus is specified in addition to the yield stress. By defining the yield stress and the elastic modulus, the stress of the film due to bending can be accurately expressed. When the degree of deformation due to bending is large and the plastic deformation of the resin constituting the insulating film becomes dominant, the yield stress can be used to express the influence of the film stress due to bending.
  • the thickness of the insulating film of this embodiment is preferably 40 to 65 ⁇ m, and more preferably 40 to 50 ⁇ m.
  • the thickness of the insulating film is less than 40 ⁇ m, since the film thickness is thin, there is a possibility that the insulating performance that can be used with a motor or a reactor cannot be exhibited. If the thickness exceeds 65 ⁇ m, the insulating film on the inner side of the bending is likely to be peeled off from the conductor wire or wrinkled at the time of bending, and the amount of solvent volatilized when coated by electrodeposition. As the amount increases, defects such as bubbles are likely to occur in the film during the baking process.
  • the rectangular conductor wire 11 of the present embodiment has a ratio of the length of the long side 11C to the short side 11A, 11B (long side / short side) of 4 or more in the rectangular cross section, and is converted into a round line.
  • the diameter is preferably 3 mm or more. This is because when the insulated wire is formed into a coil, the occupation ratio of the cross-sectional area of the conductor wire in the coil cross-sectional area can be increased.
  • the ratio of the long side / short side is 4 or more, the ratio of the long side / short side is high when an insulated wire is used with high frequency alternating current and current flows only on the surface of the conductor due to the skin effect. The region through which current flows can be widened by increasing the size.
  • the ratio of the long side / short side is preferably 50 or less, and the round wire equivalent diameter of the conductor wire is preferably 5 mm or less. This is because, during the bending process, the bending process is facilitated and the adhesiveness of the insulating film on the inner side of the bending with the conductor wire is further improved.
  • the ratio of the long side / short side exceeds 50, the flatness of the flat conductor wire becomes too large, and the conductor wire itself is liable to be twisted or cracked by bending.
  • the ratio of the long side / short side is in the range of 5 to 45.
  • the rectangular conductor wire 11 of the present embodiment has a ratio (t) of the inner layer thickness t 1 covering one short side 11 A to the outer layer thickness t 3 covering one short side 11 A via the inner layer (t 1 / t 3 ) is preferably 1 or less.
  • t 1 / t 3 is more preferably 0.14 to 1, and still more preferably 0.15 to 0.35.
  • examples of the material of the conductor wire of the insulated wire of the present embodiment include copper, copper alloy, aluminum, aluminum alloy, stainless steel and the like. Among them, a copper wire is preferable because higher conductivity can be obtained.
  • the material of the outer layer of the insulating film is polyimide (hereinafter referred to as PI) resin, polyamideimide (hereinafter referred to as PAI) resin, polyesterimide resin, acrylic resin, epoxy resin, epoxy-acrylic resin, polyester resin, polyurethane resin. And fluororesin.
  • PI polyimide
  • PAI polyamideimide
  • polyesterimide resin acrylic resin
  • epoxy resin epoxy-acrylic resin
  • polyester resin polyurethane resin
  • fluororesin a polyimide resin or a polyamide-imide resin is preferable from the viewpoint of high dielectric breakdown voltage and heat resistance.
  • Examples of the material for the inner layer of the insulating film include the above-described PI resin, PAI resin, polyesterimide resin, acrylic resin, epoxy resin, epoxy-acrylic resin, and polyester resin having a urethane skeleton or a cyclosan skeleton.
  • PI resin or a PAI resin having a urethane skeleton or a cyclosan skeleton having a relatively low elastic modulus or yield rate of the resin is preferable.
  • the insulated wire of this embodiment is manufactured by forming an insulating film on a conductor wire by a dipping method or an electrodeposition method.
  • the thickness of the film that can be applied in one film coating process is 1 to 10 ⁇ m, which is required for use as a motor or reactor for hybrid vehicles and electric vehicles.
  • the first layer that is in contact with the conductor which will be subjected to the baking process many times, becomes highly dry and causes a poor insulation when coiled due to deterioration of the film. It is necessary to devise such as drying at low temperature.
  • the flat conductor wire is placed in the insulating paint liquid stored in the insulating paint tank so that the long side of the flat conductor wire is in the vertical direction.
  • the inner layer precursor layer is formed by passing in a horizontal direction.
  • the inner layer precursor layer through which the insulating coating liquid has been passed is baked while being collected on one short side by gravity in a wet state to form an inner layer.
  • the entire rectangular conductor wire is horizontally passed through an insulating coating liquid stored in another insulating coating tank to form an outer layer precursor layer having a uniform thickness.
  • the outer layer precursor layer is baked to form an outer layer, thereby forming an insulating film composed of two layers, an inner layer and an outer layer.
  • the inner layer and the outer layer of this embodiment can be easily formed on the surface of the rectangular conductor wire, which is preferable in the present invention.
  • an electrodeposition liquid which is an insulating electrodeposition paint is separately prepared for the inner layer and the outer layer.
  • the electrodeposition liquid for the inner layer is referred to as a first electrodeposition liquid
  • the electrodeposition liquid for the outer layer is referred to as a second electrodeposition liquid.
  • Both the first electrodeposition liquid and the second electrodeposition liquid contain a polymer, an organic solvent and water.
  • it is a water dispersion type electrodeposition liquid in which a polymer is dispersed in water or a mixed dispersion type electrodeposition liquid in which a polymer is dispersed in a mixed liquid of water and an organic solvent.
  • the polymer of the first electrodeposition liquid include the resins exemplified as the material for the inner layer described above.
  • the polymer of the second electrodeposition liquid include the resins exemplified as the material for the outer layer described above.
  • both the first electrodeposition liquid and the second electrodeposition liquid are organic solvents such as N, N-dimethylformamide (DMF), N, N-dimethylacetamide (DMAc), dimethyl sulfoxide (DMSO), N-methylpyrrolidone ( NMP), ⁇ -butyrolactone ( ⁇ BL), anisole, tetramethylurea, sulfolane and the like are used.
  • NMP is preferred.
  • the first electrodeposition liquid is prepared by adding a neutralizing agent to a solution in which a PI resin or PAI resin having a urethane skeleton or a siloxane skeleton as a polymer is dissolved in NMP and DMI, and stirring the PI or PAI. After the addition, water which is a poor solvent for PI or PAI is added, mixed and stirred to prepare PI or PAI by precipitation.
  • the second electrodeposition liquid was prepared by adding a neutralizing agent to a solution of PI resin or PAI resin dissolved in NMP and DMI as a polymer and stirring to neutralize PI or PAI, and then using a poor solvent for PI or PAI.
  • the concentration of the polymer is 1 to 10% by mass with respect to 100% by mass of the mixed solvent of water and organic solvent, and the organic solvent is preferably 1 to 70% by mass.
  • the electrodeposition coating apparatus 20 shown in FIG. 2 includes a first electrodeposition tank 22 that stores a first electrodeposition liquid 21, a second electrodeposition tank 26 that stores a second electrodeposition liquid 24, and a baking furnace 27. . Both the first electrodeposition liquid 21 and the second electrodeposition liquid 24 are preferably maintained at a temperature of 5 to 60 ° C.
  • the first electrodeposition tank 22 is circular in plan view, and a cathode bar 22 a is placed in the first electrodeposition liquid 21 at one corner of the first electrodeposition tank 22 (lower part in the paper).
  • the rectangular conductor wire 11 is passed through the first electrodeposition liquid 21 at the center of the first electrodeposition tank 22.
  • the cathode bar 22a disposed in the first electrodeposition liquid 21 is grounded (see FIG. 2).
  • a planar cross-sectional view having substantially the same length as the cathode rod 22a is formed in an inverted U shape so as to surround the long side 11C and the other short side 11B of the flat rectangular conductor wire 11 that passes therethrough.
  • the insulating cover 22b is suspended so as to be positioned in the first electrodeposition liquid 21.
  • the insulating cover 22b surrounds the flat conductor wire 11 except for one short side 11A of the flat conductor wire 11, so that the flat conductor wire 11 11 is formed such that the distance from the long side 11C of the rectangular conductor wire 11 increases toward the other short side 11B.
  • One short side 11A faces the cathode bar 22a.
  • a fluororesin for example, a polytetrafluoroethylene resin is preferable.
  • the second electrodeposition tank 26 has a circular shape in plan view, and has a semi-cylindrical shape in a portion corresponding to the inner half of the second electrodeposition tank 26 (upper half in the paper).
  • the cathode plate 26 a is suspended in the vertical direction so as to be located in the second electrodeposition liquid, and the rectangular conductor wire 11 passes through the second electrodeposition liquid 24 in the center of the second electrodeposition tank 26. ing.
  • the cathode plate 26a disposed in the second electrodeposition liquid 24 is grounded (see FIG. 2).
  • a conductor wire 28 having a circular cross section wound in a cylindrical shape is electrically connected in advance via an anode 30 of a DC power source 29 in advance. Then, the conductor wire 28 having a circular cross-sectional shape is pulled up in the direction of the solid line arrow in FIG.
  • the conductor wire 28 having a circular cross-sectional shape is rolled flat by a pair of rolling rollers 31 and 31 to form a rectangular conductor wire 11 having a rectangular cross-sectional shape.
  • the rectangular conductor wire 11 is passed through the first electrodeposition liquid 21 stored in the first electrodeposition tank 22.
  • the DC voltage of the DC power supply 29 is preferably 1 to 500 V, and the DC current application time is preferably 0.01 to 60 seconds.
  • PI or PAI particles (not shown) having a negatively charged urethane skeleton or siloxane skeleton are electrodeposited on the surface of the rectangular conductor wire 11, and the inner insulating layer ( (Not shown) is formed. As shown in FIG.
  • the rectangular conductor wire 11 whose surface is covered with the inner layer precursor layer 12a proceeds to the second step, and passes through the second electrodeposition tank 26 here.
  • the rectangular conductor wire 11 passes through the second electrodeposition liquid 24 in the second electrodeposition tank 26
  • a DC voltage is applied between the rectangular conductor wire 11 and the cathode plate 26a by the DC power source 29.
  • the DC voltage of the DC power supply 29 is preferably 1 to 500 V, and the DC current application time is preferably 0.01 to 150 seconds.
  • negatively charged PI particles or PAI particles are electrodeposited on the surface of the inner layer precursor layer 12a covering the rectangular conductor wire 11, and are used for the outer layer.
  • An insulating layer (not shown) is formed.
  • the rectangular conductor wire 11 on which the inner layer precursor layer 12 a and the outer layer precursor layer that have passed through the second electrodeposition liquid 24 are formed is subjected to a baking process in a baking furnace 27.
  • the inner layer 12A and the outer layer 12B are formed on the surface of the flat conductor wire 11 as shown in the partially enlarged view of FIG. 2, and the insulated wire 10 shown in FIG. 1 is manufactured.
  • Examples of the baking furnace 27 include a near infrared heating furnace, a hot air heating furnace, an induction heating furnace, a far infrared heating furnace, and a furnace using an inert gas such as air or nitrogen whose temperature is controlled. These furnaces can be used alone or in combination. In order to increase the baking speed, it is preferable to perform hot air heating and infrared heating together.
  • the temperature of the furnace is set to 200 to 500 ° C.
  • a gas having a high flow rate is preferably used, and the gas is preferably added so that the average flow rate in the furnace is about 1 to 10 m / min.
  • the gas temperature is preferably about 200 to 500 ° C. for the same reason as the furnace temperature.
  • the baking time is preferably in the range of 1 to 10 minutes. If the heating temperature is less than 200 ° C., necessary baking cannot be performed. If the heating temperature exceeds 500 ° C., defects such as bubbles are formed in the film due to rapid volatilization of the solvent or the like at the initial stage of baking. Moreover, since it is high temperature, resin will thermally decompose.
  • the temperature of the baking process is the temperature at the center of the baking furnace.
  • the baking process is an important process that determines the adhesion of the insulating film inside the bend to the conductor wire and the softening resistance of the insulating film at high temperature when bending the insulated wire described later. If the baking is performed excessively, the insulation film peels off from the conductor wire inside the bend when the insulated wire is bent due to deterioration of the resin, interface oxidation, etc., wrinkles, or the insulation film is formed outside the bend. It may cause cracks. If the baking is insufficient, the organic solvent is excessively present in the insulating film, so that the softening temperature is lowered.
  • Manufactured into a coil by winding winding you may manufacture an insulated wire to a coil by the winding process of the flatwise bending process which bends the long side (flat surface) which the cross-sectional shape of a conductor wire makes a rectangle.
  • Example 1 With the electrodeposition coating apparatus shown in FIG. 2, a flat rectangular copper wire having a thickness of 1.5 mm and a width of 6.5 mm was coated with an insulating film as a conductor wire.
  • a water-dispersed insulating electrodeposition coating containing polyamideimide (PAI) having a 2 mass% urethane skeleton was prepared and stored in the first electrodeposition tank.
  • a water-dispersed insulating electrodeposition paint containing 2% by mass of PAI was prepared and stored in the second electrodeposition tank. As shown in FIG.
  • PAI polyamideimide
  • a cathode bar was arranged in the first electrodeposition tank, and a semi-cylindrical cathode plate was arranged in the second electrodeposition tank as shown in FIG.
  • the rectangular copper wire was allowed to pass through the centers of the first electrodeposition tank and the second electrodeposition tank.
  • the baking furnace for baking the rectangular copper wire that has passed through the second electrodeposition tank is an electric furnace (far-infrared heating furnace) having a length of 2.5 m, and a thermocouple is installed on the furnace wall,
  • the furnace can be set to a desired temperature, and a plurality of electric heaters are provided in the direction in which the copper wire advances, and the temperature can be individually set so that only a desired length can be baked.
  • the heater output was set so that only 2m range could be baked.
  • the insulated wire was manufactured by coating the flat copper wire with an insulating film under the following conditions using the electrodeposition coating apparatus having such a configuration. That is, as shown in Table 1, the DC voltage was set to 100 V, the temperatures of the first electrodeposition liquid and the second electrodeposition liquid were adjusted to about 20 ° C., and the electrodeposition time of the first electrodeposition tank was 10 Second, the electrodeposition time of the second electrodeposition tank was adjusted to 130 seconds. These electrodeposition times were performed by adjusting the amount of each of the first electrodeposition liquid and the second electrodeposition liquid stored in the first electrodeposition tank and the second electrodeposition tank.
  • the baking furnace was set to 300 ° C., and was dried and heat-treated in the furnace for 5 minutes.
  • Example 2 to 6 Comparative Examples 1 to 3> The main components of the first and second electrodeposition liquids, the long and short sides of the rectangular conductor wire, the rounded wire equivalent diameter of the rectangular conductor wire, and the manufacturing conditions of the insulated wire were changed as shown in Table 1, and the others In the same manner as in Example 1, insulated wires of Examples 2 to 6 and Comparative Examples 1 to 3 were produced.
  • Example 4 an insulated wire was manufactured using a water-dispersed insulating electrodeposition paint containing PI having a siloxane skeleton as the first electrodeposition liquid.
  • Comparative Examples 1 to 3 the insulated wire was manufactured by allowing the flat wire conductor wire to pass through only the second electrodeposition liquid without passing the first electrodeposition liquid. As shown in FIG.
  • the electrodeposition tank at this time was circular in a plan view, and a cylindrical cathode plate 36 a was disposed on the entire inner periphery of the electrodeposition tank 36.
  • the rectangular conductor wire 11 was allowed to pass through the electrodeposition liquid 34 in the center of the electrodeposition tank 36.
  • the indentation elastic modulus was measured at a position of about 2 ⁇ m from the conductor on the short side A side, and at the position of 5 ⁇ m from the outer periphery of the film when measuring the outer layer for the sample obtained by exposing the cross section obtained earlier.
  • Thickness of insulating film (t 1 , t 2 , t 3 )
  • the thicknesses (t 1 , t 2 ) of one short side A and the other short side B of the inner layer of the insulating film were determined by preliminary prediction. Specifically, under the conditions shown in Table 1, electrodeposition was performed using only the first electrodeposition tank, and baking was performed to produce an insulated wire. About 1 cm of the produced insulated wire was cut out, embedded in an epoxy resin, and the resin and the insulated wire were polished to produce a sample in which the cross section of the insulated wire was exposed.
  • the thickness of the inner layer and the outer layer can be measured by ESD analysis using SEM. Good.
  • the elastic modulus and the film thickness may be simultaneously measured by measuring the elastic modulus in detail in the film thickness direction for the sample whose cross section is exposed in the micro indentation depth test.
  • Adhesiveness of insulating film 10cm of insulated wire is cut out, and this is used for the edgewise bending process of the insulated wire along with a self-diameter round bar using the equipment used to coil the motor and reactor. Then, it was bent 90 degrees so that the radius of bending was the self-diameter of the insulated wire.
  • the bent insulated wire was magnified 20 times with an optical microscope, and the inner side of the insulating film was checked for wrinkles and peeling (adhesion).
  • the insulated wire of the present invention can be used for coils used in reactors and motors for hybrid vehicles and electric vehicles.

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PCT/JP2018/006268 2017-03-22 2018-02-21 絶縁電線、その製造方法、これを用いたコイルの製造方法及びコイル WO2018173608A1 (ja)

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EP18772228.5A EP3605558B1 (de) 2017-03-22 2018-02-21 Isolierter elektrischer draht, herstellungsverfahren dafür, spule und spulenherstellungsverfahren unter verwendung davon
CN201880014473.3A CN110352463B (zh) 2017-03-22 2018-02-21 绝缘电线、其制造方法、使用该绝缘电线的线圈的制造方法及线圈
US16/493,801 US11581127B2 (en) 2017-03-22 2018-02-21 Insulated electric wire, production method therefor, coil and coil production method using same

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JP7238817B2 (ja) * 2020-02-03 2023-03-14 トヨタ自動車株式会社 配策材およびその製造方法
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US20200035407A1 (en) 2020-01-30
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